Rack-mounted server and associated methods

ABSTRACT

An improved rack-mounted server comprises, in one embodiment, a slidable electronics tray having a top cover secured to the rack, to facilitate access to the tray when it is withdrawn from the rack. The tray also includes a camming mechanism to facilitate insertion of the tray into and its extraction from cable connectors or plugs affixed to the rack. The tray includes, in one embodiment, a movement detection mechanism to power it up or down when tray insertion or removal, respectively, is initiated. In addition, the rack includes an improved cable management system that can acconmmodate different cables and cable plugs. As a tray is inserted into or removed from the rack, corresponding connectors on the tray are electrically coupled to or uncoupled from cable plugs affixed to the rack, eliminating any need to remove cables from the tray or reinstall them.

TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates generally to electronics packaging.More particularly, the present invention relates to an improvedrack-mounted server that facilitates access to and/or replacement ofelectronics trays, and to methods of use thereof.

BACKGROUND OF THE INVENTION

[0002] Computer networks, such as the Internet, utilize high performancecomputer systems called “servers”. Servers typically have highperformance processors and contain hardware and software capable ofhandling large amounts of data. Servers provide a large number ofcomputer users with access to large stores of information. For example,servers are used to host web sites that can be accessed by manycomputers via the Internet.

[0003] One or more server components are often housed within a serverhousing or “server rack”. Server racks are typically box-like structuresor cabinets that contain a number of removable electronic modules orelectronic trays (“e-trays”). Each e-tray can be a different server, oreach e-tray can hold one or more components of a server. Servercomponents can include modules, for example, for processors, disk drives(such as floppy disk drives, hard drives, compact disk or CD drives, anddigital video disk or DVD drives), random access memory (RAM), networkinterfaces and controllers, SCSI (small computer systems interface) buscontrollers, video controllers, parallel and serial ports, powersupplies, and so forth.

[0004]FIG. 1 is a perspective view of a portion of a prior art serverrack 1 and electronics tray 2. E-tray 2 can be a box-like housing havingmetal side panels 3, a top panel or cover 4, a bottom panel or base (notshown), and a front panel 5. These panels help to reduce the effect ofpotentially harmful electromagnetic interference (EMI), and to minimizethe impact of various environmental factors such as dust. When a priorart e-tray 2 is removed from a server rack 1 for servicing, it isnecessary to remove the cover 4 prior to servicing and to replace thecover 4 after servicing. This is a time-consuming operation with respectto relatively expensive equipment that is normally expected to operatewith a minimum of down-time.

[0005] The various server components are electrically and functionallyinterconnected via wires or cables. Generally, in the prior art thereare many cables coming out of at least one side, and sometimes severalsides, of the server rack. Cables typically have an end connector or“cable plug” that fastens to a corresponding electrical “receptacle” onthe e-tray. The cable plug and receptacle can be male, female, oranother type of connector. Each e-tray can have multiple receptaclesthat require connection to corresponding multiple cable plugs.

[0006] “Cable management” is the implementation of a system whose objectis to control the arrangement of the plethora of power and signal cablesthat run into and out of an electronic housing, such as a server rack.Many known server racks include dozens of cables in unsightly,disorganized, and potentially dangerous states of disarray.

[0007] As mentioned earlier, servers and their components, which arecontained in e-trays, are expected to be highly reliable. When a servercomponent requires servicing, the amount of time and effort expended inremoving the e-tray should be kept to a minimum, and the same is truewhen the e-tray is ready to be reinserted into the server rack.

[0008] When a prior art e-tray is removed from a server rack, theservice person may neglect to first power-down the e-tray. This canresult in harmful arcing across the terminals of power supplyconnectors, to the extent that the terminals are often fused and willneed to be replaced, thus incurring even more time and effort before thee-tray can be reinserted into the server rack. In addition, the serviceperson can be exposed to potentially hazardous conditions.

[0009] For the reasons stated above, and for other reasons stated belowwhich will become apparent to those skilled in the art upon reading andunderstanding the present specification, there is a significant need inthe art for improved rack-mounted servers and methods of making suchequipment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a perspective view of a portion of a prior art serverrack and electronics tray;

[0011]FIG. 2 is a front perspective view of a portion of an electronicstray and top cover, in accordance with one embodiment of the invention;

[0012]FIG. 3 is a front perspective view of an electronics tray, inaccordance with one embodiment of the invention;

[0013]FIG. 4 is a front perspective view of a portion of a server rack,including a fixed electronics tray cover, in accordance with oneembodiment of the invention;

[0014]FIG. 5 is a front perspective view of a server rack, in accordancewith one embodiment of the invention;

[0015]FIG. 6 is a front perspective view of an electronics tray within atray cover, in accordance with one embodiment of the invention;

[0016]FIG. 7 is a front perspective view of a portion of an electronicstray in which an insertion/extraction element is in a first position, inaccordance with one embodiment of the invention;

[0017]FIG. 8 is a front perspective view of a portion of an electronicstray in which an insertion/extraction element is in a second position,in accordance with one embodiment of the invention;

[0018]FIG. 9 is a front perspective view of a portion of an electronicstray in which an insertion/extraction element is in a third position, inaccordance with one embodiment of the invention;

[0019]FIG. 10 is a side view of a handle of an electronics tray in afully upright position in which the switch arm of a switch is depressed,and FIG. 10 further shows a power-up/power-down circuit, in accordancewith one embodiment of the invention;

[0020]FIG. 11 is a rear perspective view of a cable-clamping mechanism,in accordance with one embodiment of the invention;

[0021]FIG. 12 is a front perspective view of a cable-clamping mechanism,in accordance with one embodiment of the invention;

[0022]FIG. 13 is an exploded front perspective view of a cable-clampingmechanism, in accordance with one embodiment of the invention;

[0023]FIG. 14 is a rear perspective view of an electronics tray havingelectrical receptacles that are completely inserted into correspondingcable plugs of a cable-clamping mechanism, in accordance with oneembodiment of the invention; and

[0024]FIG. 15 is a rear perspective view of an electronics tray havingelectrical receptacles that are completely removed from correspondingcable plugs of a cable-clamping mechanism, in accordance with oneembodiment of the invention;

[0025]FIG. 16 is a front perspective view of a portion of a server rackhaving an integral connector to couple to an electronics tray, inaccordance with an embodiment of the invention;

[0026]FIG. 17 is a zoomed-in front perspective view of the integralconnector shown in FIG. 16 and of an adapter card on which the integralconnector is mounted;

[0027]FIG. 18 is a front perspective view of the integral connector andadapter card shown in FIGS. 16 and 17;

[0028]FIG. 19 is a rear perspective view of the integral connector andadapter card shown in FIG. 18 and of various cables plugged intocorresponding connectors on the adapter card; and

[0029]FIG. 20 is a flow diagram illustrating a method of forming anelectronics rack assembly, in accordance with one embodiment of theinvention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0030] In the following detailed description of embodiments of theinvention, reference is made to the accompanying drawings which form apart hereof, and in which is shown by way of illustration specificpreferred embodiments in which the inventions may be practiced. Theseembodiments are described in sufficient detail to enable those skilledin the art to practice the invention, and it is to be understood thatother embodiments may be utilized and that mechanical, compositional,structural, electrical, and procedural changes may be made withoutdeparting from the spirit and scope of the present invention. Thefollowing detailed description is, therefore, not to be taken in alimiting sense, and the scope of the present invention is defined onlyby the appended claims.

[0031] The present invention provides a solution to the need for quickaccess to electronic modules, such as e-trays, to enable such modules tobe inspected, repaired, replaced, or upgraded quickly. Variousembodiments are illustrated and described herein.

[0032]FIG. 2 is a front perspective view of a portion of an electronicstray 10 and top cover 12, in accordance with one embodiment of theinvention. Top cover 12 comprises a metal panel and a pair of sidewalls17 and 18 coupled at substantially right angles to the plane of themetal panel.

[0033] E-tray 10 comprises a base or bottom panel 11 on which one ormore electronic components can be mounted, such as a disk drive (notshown) whose housing 20 is located on base 11. Typically, severalelectronic components are located on base 11. These components can beany of the components mentioned earlier.

[0034] E-tray 10 also comprises a front panel 19, a pair of opposingsides or side panels 13 and 14, and a back panel (not shown in FIG. 2).Each side 13 and 14 has a suitable mounting element to couple it to theinside of the corresponding sidewall 17 or 18, respectively, of topcover 12. In one embodiment, the mounting elements comprise mating railassemblies or drawer glides. An inner drawer glide 15 and 16 is mountedon each side 13 and 14, respectively. A mating outer drawer glide (notshown in FIG. 2) is mounted on the inside surface of each sidewall 17 or18 of top cover 12. In other embodiments, other types of mountingelements could be used, such as tongue-and-groove arrangements,rod-and-eyelet arrangements, box-within-a-box arrangements, or the like.

[0035] The mounting elements permit the e-tray 10 to be insertedsubstantially within the top cover 12 of the server rack or to bewithdrawn from the top cover 12 of the server rack. Top cover 12substantially covers e-tray 10 when it is inserted within the serverrack, and top cover 12 remains affixed to the server rack when thee-tray 10 is withdrawn from the server rack.

[0036] Also seen in FIG. 2 is e-tray handle 30 used to insert e-tray 10into its rack and to extract it from its rack. E-tray handle 30 will bediscussed in greater detail below.

[0037]FIG. 3 is a front perspective view of an electronics tray 10, inaccordance with one embodiment of the invention. This view of e-tray 10is an enlarged view of e-tray 10 shown in FIG. 2. Rear panel 24 ofe-tray 10, having airflow openings 21, can be seen in this figure.Otherwise, all elements are substantially as previously shown in FIG. 2.

[0038]FIG. 4 is a front perspective view of a portion of a server rack40, including a fixed electronics tray top cover 12, in accordance withone embodiment of the invention. While only one e-tray top cover 12 isshown in FIG. 4 for ease of illustration, typically there are a numberof e-tray covers 12 mounted in server rack 40, one for each e-tray thatneeds to be inserted into server rack 40.

[0039] Server rack 40 comprises a pair of opposing sides 41 and 42. Eachside 41 or 42 supports a respective sidewall 17 or 18 (FIG. 2) of e-traytop cover 12. In turn, the sidewall 17 or 18 of each e-tray top cover 12has a suitable mounting element to couple it to the outside of thecorresponding side 13 or 14, respectively, of e-tray 10 (FIG. 3). In oneembodiment, the mounting elements comprise mating drawer glides. Anouter drawer glide 43 and 44 is mounted to the inside surface of eachsidewall 17 or 18, respectively, of e-tray top cover 12. Alternatively,the mounting elements could be mounted directly to the inside surfacesof sides 41 and 42, respectively, of server rack 40.

[0040] Also seen in FIG. 4 is a power supply module 45 comprising aplurality of cooling fan inlets or vents 46.

[0041] Server rack 40 can also include other elements that are notillustrated in FIG. 4 for ease of illustration, such as a wheeled base,fascia panels, a top panel, or the like, none of which are germane tothe present invention.

[0042]FIG. 5 is a front perspective view of a server rack 40, inaccordance with one embodiment of the invention. The server rack 40 seenin FIG. 5 is a fully populated version of the server rack 40 shown inFIG. 4. In FIG. 5, server rack 40 comprises a plurality of e-trays 10,all of which are shown to be fully inserted into server rack 40. E-trays10 are removably mounted between the sides 41 and 42 of server rack 40and, more specifically, between the sidewalls of their respective e-traytop covers (e.g. top cover 12, FIG. 4). Also shown in FIG. 5 is the topcover 12 for the uppermost e-tray 10 in server rack 40. Top cover 12provides EMI shielding, protection from environmental factors, and asafety enclosure for e-tray 10. Each e-tray 10 in server rack 40 has acorresponding top cover 12.

[0043]FIG. 6 is a front perspective view of an electronics tray 10within a tray top cover 12, in accordance with one embodiment of theinvention. The view of e-tray 10 in FIG. 6 is similar to that of e-tray10 in FIG. 2, except that in FIG. 5 e-tray 10 is positioned fully withintray top cover 12. Also, as seen in FIG. 6, the side or sidewall 18 oftop cover 12 can include a flange 49 or other suitable element withwhich to secure top cover 12 to server rack 40 (FIG. 5) using suitablefasteners (not shown).

[0044]FIG. 7 is a front perspective view of a portion of an electronicstray 10 in which an insertion/extraction element is in a first position,in accordance with one embodiment of the invention. To provide thereader with a proper understanding of the location of theinsertion/extraction element, FIG. 7 shows a portion of electronics tray10 and a portion of top cover 12.

[0045] The insertion/extraction element comprises, in this embodiment, acam member or cam arm 51 on the end of handle 30. When handle 30 ispulled in the direction indicated by arrow 53, cam arm 51 swivels aboutshaft 50. Shaft 50 is affixed to the front panel 19 of e-tray 10 by abracket (not visible in FIG. 7 but viewable in FIG. 9).

[0046] Cam arm 51 engages an engaging element on the server rack. In theembodiment illustrated in FIG. 7, the engaging element is a cam receiver52, which is affixed to the inside surface of sidewall 18 of top cover12. When handle 30 is pulled in the direction indicated by arrow 53, itwill cause e-tray 10 to be pulled out of top cover 12.

[0047] Also, barely perceptible in FIG. 7, but more apparent in FIGS. 8and 9, is a portion of switch arm 60, which is engaged by handle 30 whenhandle 30 is in the upright position as shown in FIG. 7.

[0048] The insertion/extraction mechanism provides a significantmechanical advantage to overcome high frictional forces that often occurbetween mating connectors on the server rack and e-tray, such as betweencable plugs on the rack and electrical receptacles on the e-tray.

[0049]FIG. 8 is a front perspective view of a portion of an electronicstray 10 in which an insertion/extraction element is in a secondposition, in accordance with one embodiment of the invention. In FIG. 8,handle 30 has been pulled down approximately halfway between the uprightposition shown in FIG. 7 and the position shown in FIG. 9.

[0050] Visible in FIG. 8 is switch arm 60, which can be contoured to theshape of handle 30. Switch arm 60 is coupled to a switch shaft 62 thatpasses through aperture 64 in the front panel 19 of e-tray 10 andconnects with switch 66 (FIG. 10).

[0051]FIG. 9 is a front perspective view of a portion of an electronicstray 10 in which an insertion/extraction element is in a third position,in accordance with one embodiment of the invention. In FIG. 9, handle 30has been pulled all of the way down, so that cam arm 51 is no longerengaged with cam receiver 52.

[0052] Bracket 54 affixed to the front panel 19 of e-tray 10 serves as asupport for shaft 50, about which cam arm 51 pivots when handle 30 ismoved.

[0053]FIG. 10 is a side view of a handle 30 of an electronics tray in afilly upright position in which switch arm 60 of switch 66 is depressed,and FIG. 10 further shows a power-up/power-down circuit 70, inaccordance with one embodiment of the invention. Switch arm 60 iscoupled to switch 66 via a switch shaft 62 that passes through aperture64 in the front panel 19 and connects with switch 66. Switch 66 can beany of suitable type, such as a micro-switch. In other embodiments,switch 66 can be actuated by any other appropriate kind of movementsensor, such as a magnetic element, pneumatic element, pressuretransducer, light-beam interrupter, radio-frequency (RF) device, or thelike.

[0054] While switch 66 is shown close to handle 30 in the embodimentillustrated in FIG. 10, in other embodiments, the movement sensor orswitch could be located on the handle 30 itself, elsewhere on thee-tray, or elsewhere in the server rack. For example, it could belocated at the rear of the e-tray.

[0055] Switch 66 is coupled via a link 68 to a power-up/power-downcircuit 70. Link 68 can be of any suitable type, such as an electricallyconductive bus or cable, fiber optic cable, RF or infrared link, or thelike, depending in part upon the type of switch 66 employed. Switch 66transmits an “E-Tray In” signal via link 68 when handle 30 is in thefilly upright position, and switch 66 transmits an “E-Tray Out” signalwhen handle 30 has been moved from the filly upright position.

[0056] Power-up/power-down circuit 70 is coupled to power supply 72.Power-up/power-down circuit 70 is responsive to the E-Tray In signal toinitiate a power-up sequence, coupling electrical power having theproper parameters to the electrical component(s) on the e-tray.Likewise, power-up/power-down circuit 70 is responsive to the E-Tray Outsignal to initiate a power-down sequence, uncoupling electrical powerfrom the electrical component(s) on the e-tray. It is well within theskill of those of ordinary skill in the art to design an appropriatepower-up/power-down circuit 70. The response characteristics ofpower-up/power-down circuit 70 can be tuned so that a power-downsequence is initiated within a very short time after handle 30 ispulled, e.g. within 300 milliseconds.

[0057] By ensuring that power is not turned on while the e-tray isinserted or removed, the potential for damage to electronic componentson the e-tray and/or to the connector terminals of receptacles and cableplugs (such as those illustrated in FIGS. 11-15) is substantiallyreduced. In addition, because it is impossible to remove the e-traywithout shutting down the power, the margin of safety for operationalpersonnel is enhanced, which is particularly important for e-trays whosetop covers remain in the server rack when the e-trays are removed.

[0058]FIG. 11 is a rear perspective view of a cable-clamping mechanism100, in accordance with one embodiment of the invention. Cable-clampingmechanism 100 comprises a pair of mating elements 102 and 104. Matingelements 102 and 104 have formed therein a plurality of openings121-125. Certain ones of openings 121-125 have differing physicaldimensions in the embodiment shown in FIG. 11, but in alternativeembodiments they could all have the same physical dimensions. Openings121-124 accommodate cable plugs 131-134 of cables 111-114, respectively,and opening 125 accommodates two cable plugs 135-136 of cables 115-116.

[0059] One or more securing elements in the form of fasteners 106 and107 secure cable-clamping mechanism 100 to a structural member at therear of the server rack. In the embodiment illustrated in FIGS. 14 and15, the structural member comprises rear panel 34 of top cover 12;however, a different structural member could be used in anotherembodiment. Because cable-clamping mechanism 100 is secured to theelectronics rack assembly via top cover 12, cable plugs 131-136 arefirmly held in place when corresponding mating receptacles at the rearof the e-tray are inserted into cable plugs 131-136, as the e-tray isinserted into the electronics rack assembly, as will be seen in greaterdetail below regarding FIGS. 14 and 15.

[0060]FIG. 12 is a front perspective view of a cable-clamping mechanism100, in accordance with one embodiment of the invention. The view ofcable-clamping mechanism 100 in FIG. 12 is from the opposite side ofthat seen in FIG. 11. Otherwise, all elements in FIG. 12 aresubstantially as shown in FIG. 11. Also seen in FIG. 12 is an additionalfastener 108, which can be like fasteners 106 and 107. In oneembodiment, fasteners 106-108 are shoulder screws. Fasteners 106-108preferably provide a degree of “float” or tolerance between the cableplugs of cable-clamping mechanism 100 and their mating receptacles 101at the rear of e-tray 10, in order to accommodate variability andtolerances in the assembly parts.

[0061]FIG. 13 is an exploded front perspective view of a cable-clampingmechanism 100, in accordance with one embodiment of the invention. Theview of cable-clamping mechanism 100 in FIG. 13 is from the same side asthat in FIG. 12; however, the perspective is from the other end ofcable-clamping mechanism 100. The openings 121-125 within matingelements 102 and 104 can be clearly seen in FIG. 13.

[0062] Opening 121 comprises a retention element in the form of groove146. Groove 146 mates with a corresponding retention element in the formof a ridge 144 of cable plug 131 to help maintain cable plug 131 in afixed position within opening 121 of cable-clamping mechanism 100,particularly when insertion or withdrawal forces are applied to cableplug 131.

[0063] Fastening elements, such as screws 141-142, can be employed tofasten mating elements 102 and 104 together. Only two screws 141-142 areshown here for ease of illustration.

[0064]FIG. 14 is a rear perspective view of an electronics tray topcover 12 having electrical receptacles (not shown) that are completelyinserted into corresponding cable plugs (not shown) of a cable-clampingmechanism 100, in accordance with one embodiment of the invention.

[0065] In FIG. 14, a structural member in the form of top cover rearpanel 34 at the rear of the server rack supports cable-clampingmechanism 100. If a structural member other than rear panel 34 is used,it can be secured at any convenient location, such as between the sides41-42 (FIG. 4) of server rack 40 or, in an embodiment where top coverhas no rear panel, between the sidewalls 17-18 (FIG. 2) of top cover 12(FIG. 2).

[0066]FIG. 15 is a rear perspective view of an electronics tray 10having electrical receptacles 101 that are completely removed fromcorresponding cable plugs of a cable-clamping mechanism 100, inaccordance with one embodiment of the invention. The view in FIG. 15 islooking up at the bottom 11 of e-tray 10. E-tray 10 has been withdrawnsufficiently to decouple receptacles 101 from the cable plugs ofcable-clamping mechanism 100, but e-tray 10 has not been completelywithdrawn from top cover 12.

[0067] Also seen in FIG. 15 is the outer member 44 of a drawer glide onthe inside surface of sidewall 18 of top cover 12. If desired, suitabledrawer-retaining elements can be provided on the e-tray 10 to preventits removal from the drawer glides of top cover 12 without positivehuman intervention, e.g. by depressing or lifting appropriate detents,catches, or tabs (not shown).

[0068] Rear panel 34, having airflow openings 31, provides support forcable-clamping mechanism 100.

[0069]FIG. 16 is a front perspective view of a portion of a server rack202 having an integral connector 222 to couple to an electronics tray200, in accordance with an embodiment of the invention. In thisembodiment, electronics tray 200 can be similar or identical to a priorart electronics tray, such as electronics tray 2 illustrated in FIG. 1,in that electronics tray 200 has a top cover 204 that remains in placeon electronics tray 200 when electronics tray 200 is withdrawn from theserver rack 202.

[0070] However, in other embodiments, electronics tray 200 can be of thesame type as electronics tray 10 illustrated in FIG. 2, for example,having a top cover 12 that is affixed to the server rack 40 and thatremains in place on the server rack 40 when the electronics tray 10 iswithdrawn from the server rack 40.

[0071] Electronics tray 200 can be slide into and out of server rack 202through the use of suitable drawer glides, such as inner drawer glide206 on electronics tray 200 and outer drawer glide 208 mounted on sidestructural members or side panels 210 of server rack 202.

[0072] In this embodiment, a single integral connector 222 is mounted onan adapter card 220, which in turn is mounted on a rear structuralmember or rear panel 226. A plurality of various cables 224 are coupledto the rear side (refer to FIG. 19) of adapter card 220. Whenelectronics tray 200 is inserted into server rack 202, a single integralconnector 222 is mated to a corresponding mating connector (not shown)at the rear of electronics tray 200.

[0073] The electronics tray connector can be of opposite “gender” tothat of integral connector 222. In one embodiment, connector 222 is anedge connector, and its mating connector on electronics tray 200comprises PCB traces on a protruding “tongue” at the rear of electronicstray 200 in an arrangement wherein each trace is gripped by an opposingpair of contacts within the edge connector when the tongue is insertedinto the edge connector.

[0074] In another embodiment, connector 222 could be a D-type multi-pinconnector, and its mating receptacle on electronics tray 200 could be aD-type multi-holed receptacle. However, the invention is not limited toany particular type of connector or receptacle.

[0075] By reducing several diverse cable plugs down to a single integralconnector 222, the insertion force and insertion tolerances areconsiderably reduced. In another embodiment, several groups of cableplugs could each be electrically coupled to a respective integralconnector, i.e. a first group of cable plugs could be coupled to a firstintegral connector, a second group of cable plugs could be coupled to asecond integral connector, and so forth.

[0076]FIG. 17 is a zoomed-in front perspective view of the integralconnector 222 shown in FIG. 16 and of an adapter card 220 on which theintegral connector 222 is mounted. FIG. 17 shows slightly more detail ofthe integral connector 222 and adapter card 220 and how they are mountedon rear panel 226. Adapter card 220 is coupled to a correspondingaperture (not shown) in rear panel 220 in a manner that allows adaptercard 220 to float and to provide a certain amount of horizontal andvertical insertion tolerance between integral connector 222 and itsmating connector on the rear side of electronics tray 200.

[0077]FIG. 18 is a front perspective view of the integral connector 222and adapter card 220 shown in FIGS. 16 and 17. FIG. 18 shows slightlymore detail of the integral connector 222 and adapter card 220 in thisparticular view, in which adapter card 220 is not mounted on rear panel226. Adapter card 220 can be a single-layered or multi-layered PCB orother substrate of any suitable material. The internal electrical tracesof adapter card 220 serve to couple individual connective elements, suchas pins or contacts, within integral connector 222 to correspondingconnective elements within plug receptacles on the opposite side ofintegral connector 222 that mate with the cable plugs, as will be seenin greater detail in FIG. 19, which will now be described.

[0078]FIG. 19 is a rear perspective view of the adapter card 220 shownin FIG. 18 and of various cables 224 plugged into corresponding cableconnectors on the adapter card 220. Adapter card 220 has a plurality ofcable connectors, such as cable connectors 232 and 234, mounted on itsrear side. Each cable connector, such as cable connectors 232 and 234,for example, mates with a corresponding cable plug, such as cable plugs231 and 233, respectively. The cable plugs 231 and 233, and the cableconnectors 232 and 234, shown in FIG. 19 are merely illustrative, andany types of cable plugs and cable connectors can be employed.

[0079]FIG. 20 is a flow diagram illustrating a method of forming anelectronics rack assembly, in accordance with one embodiment of theinvention. The method begins at 150.

[0080] In 152, a rack assembly is formed having a pair of opposing sides(e.g. sides 41 and 42, FIG. 5).

[0081] In 154, a plurality of e-trays are provided (e.g. e-trays 10,FIG. 5). Each e-tray has a cover comprising a metal panel to which arecoupled a pair of sidewalls (e.g. e-tray 10 having bottom panel 11 andsidewalls 13-14, FIG. 3).

[0082] In 156, a cover for each e-tray is affixed to the rack assemblyby coupling each cover sidewall to a respective one of the rack assemblysides (e.g., to rack assembly sides 41-42, FIG. 4). In oneimplementation, for example, outer drawer glide members (e.g. outerdrawer glides 43-44, FIG. 4) are provided on the rack assembly sides,and inner drawer glide members (e.g. inner drawer glides 15-16, FIG. 3)are provided on the e-tray sidewalls. The respective inner and outerdrawer glide members are coupled (e.g. as illustrated in FIG. 2).

[0083] The operations described above with respect to the methodillustrated in FIG. 20 can be performed in a different order from thatdescribed herein. Also, it should be understood that although an “End”block is shown for the method, it may be continuously performed.

Conclusion

[0084] The present invention provides for a server rack having aplurality of e-trays that can be easily, quickly, and safely removed andreinserted. Embodiments have been disclosed in which the e-tray top isaffixed to the server rack, so that it does not have to be removed andreplaced when the e-tray is withdrawn for inspection, repair,replacement, and/or upgrade.

[0085] Also, by providing an automatic power-down facility, an e-traythat is withdrawn by a repair person without first powering it down doesnot sustain potential damage to its connector terminals or to itselectronic components.

[0086] Further, by providing a cable management solution that enablese-trays to be removed and replaced without associated time-consumingremoval and replacement of wires and cables, the performance of theserver equipment is substantially enhanced, and it is therefore morecommercially attractive. The cable management solution described hereinprovides a persistent interface that virtually constitutes aninput/output socket at the system level, substantially facilitating theinsertion and removal of electronic modules into an electronic assembly.

[0087] As shown herein, the present invention can be implemented in anumber of different embodiments. Other embodiments will be readilyapparent to those of ordinary skill in the art. The elements, materials,geometries, dimensions, and sequence of operations can all be varied tosuit particular server rack and e-tray requirements.

[0088] The invention should not be construed as restricted to serverracks, and it may find application in any type of electronic assemblystructure. For example, it can be used for telecommunications equipment,power industry equipment, industrial equipment, radio and televisionbroadcasting equipment, aerospace and military equipment, maritimeequipment, automotive equipment, and personal entertainment equipment(e.g., televisions, radios, stereos, tape and compact disc players,video cassette recorders, MP3 (Motion Picture Experts Group, Audio Layer3) players, etc.), and the like. Thus, as used herein, the terms “serverrack” or “electronics rack assembly” are intended to mean any type ofelectronic assembly structure.

[0089] Further, the terms “electronics tray” and “e-tray” are intendedto mean any type of electronic modules, such as removable electronicsboards, panels, cards, or other types of electronic modules.

[0090] While cable plugs are described herein as located on the serverrack, and receptacles are described as located on the e-trays, theinverse could also be implemented in other embodiments.

[0091] While a top panel has been described as being fixed in the rack,in another embodiment, the bottom panel could be fixed, and the e-traycould be inverted for example. Also, while a separate power-downmechanism for each e-tray has been disclosed, in another embodiment asingle power-down mechanism could be provided for the entire server rackor a portion thereof using, for example, a light beam arrangement todetect any withdrawal and accordingly to shut down the entire serverrack or portion thereof.

[0092] The terms “top”, “bottom”, “front”, and “back” are to beunderstood as relative terms, and it should be understood that the scopeof the invention includes corresponding elements in structures that maybe inverted or turned end-for-end relative to those shown in the figuresand described herein.

[0093] The above-described choice of materials, geometry, structure, andassembly operations can all be varied by one of ordinary skill in theart to optimize the accessibility of server racks and e-trays and tominimize the time required to inspect, repair, and/or replace e-trays.The particular implementation of the invention is very flexible in termsof the orientation, size, number, and composition of its constituentelements. Various embodiments of the invention can be implemented usingany one or more of various geometrical and functional arrangements ofe-tray covers, power-up/power-down mechanisms, insertion/removalmechanisms, and cable management systems to achieve the advantages ofthe present invention.

[0094] The figures are merely representational and are not drawn toscale. Certain proportions thereof may be exaggerated, while others maybe minimized. FIGS. 2-16 are intended to illustrate variousimplementations of the invention that can be understood andappropriately carried out by those of ordinary skill in the art.

[0095] Although specific embodiments have been illustrated and describedherein, it will be appreciated by those of ordinary skill in the artthat any arrangement that is calculated to achieve the same purpose maybe substituted for the specific embodiment shown. This application isintended to cover any adaptations or variations of the presentinvention. Therefore, it is manifestly intended that this invention belimited only by the claims and the equivalents thereof.

What is claimed is:
 1. An electronics tray to mount in a server rack andcomprising: a housing having a base and a plurality of sides; at leastone electronic component on the base; mounting elements on two opposingsides to couple to the server rack to permit the electronics tray to beinserted substantially within the server rack or to be withdrawn fromthe server rack; and a cover to be affixed to the server rack and tosubstantially cover the electronics tray when it is insertedsubstantially within the server rack, and to remain affixed to theserver rack when the electronics tray is withdrawn from the server rack.2. The electronics tray recited in claim 1, wherein the mountingelements comprise drawer glides.
 3. The electronics tray recited inclaim 1, wherein the cover comprises: a metal panel; and a pair ofsidewalls on opposite sides of the panel and coupled at right angles tothe panel.
 4. An electronics rack assembly comprising: a pair ofopposing sides; and a plurality of electronics trays removably mountedbetween the sides, each electronics tray comprising a cover affixed tothe sides to substantially cover the electronics tray when it ispositioned substantially within the electronics rack assembly, and toremain affixed to the electronics rack assembly when the electronicstray is withdrawn from the electronics rack assembly.
 5. The electronicsrack assembly recited in claim 4, wherein the plurality of electronicstrays are mounted to the sides with mounting elements comprising drawerglides.
 6. The electronics rack assembly recited in claim 4, whereineach cover comprises: a metal panel; and a pair of sidewalls on oppositesides of the panel and coupled at right angles to the panel.
 7. Theelectronics rack assembly recited in claim 6, wherein each of thesidewalls for each cover is coupled to a respective one of the sides. 8.A method comprising: forming a rack assembly comprising a plurality ofelectronics trays removably mounted in the rack assembly; and affixing acover for each electronics tray to the rack assembly.
 9. The methodrecited in claim 8, wherein the rack assembly comprises a pair ofopposing sides, wherein each cover comprises a metal panel to which arecoupled a pair of sidewalls, and wherein each sidewall for each cover iscoupled to a respective one of the sides.
 10. The method recited inclaim 9, wherein forming a rack assembly comprises: providing mountingelements comprising drawer glides, each having an inner member and anouter member; coupling the inner member of each drawer glide to anelectronics tray; and coupling the outer member of each drawer glide toa respective one of the sides.
 11. An electronics tray to be mounted inan electronics rack assembly and comprising: a housing having a base anda plurality of sides; at least one electronic component on the base;mounting elements on two opposing sides to couple to the electronicsrack assembly to permit the electronics tray to be positionedsubstantially within the electronics rack assembly or to be withdrawnfrom the electronics rack assembly; and a handle coupled to the housingand comprising a member to engage with an engaging element on theelectronics rack assembly.
 12. The electronics tray recited in claim 11,wherein the engaging element comprises a switch arm.
 13. The electronicstray recited in claim 12, wherein the handle is pivotable between afirst position and a second position, and wherein the member is toengage the switch arm in the first position and to disengage the switcharm in the second position.
 14. The electronics tray recited in claim11, wherein the engaging element comprises a cam receiver.
 15. Theelectronics tray recited in claim 14, wherein the handle is pivotablebetween a first position and a second position, wherein the membercomprises a cam arm to engage the cam receiver, and wherein the cam armis to engage the cam receiver in the first position and to disengage thecam receiver in the second position.
 16. An electronics rack assemblycomprising: a pair of opposing sides and a rear side; at least one cableplug affixed at the rear side; and at least one electronics traycomprising: a housing having a base, a front panel, and a rear panel; atleast one electronic component on the base and electrically coupled to areceptacle at the rear panel; mounting elements on the housing to coupleto the electronics rack assembly to permit the electronics tray to bepositioned substantially within the electronics rack assembly and to bewithdrawn from the electronics rack assembly; and a handle coupled tothe housing and comprising a member to engage with an engaging elementon the electronics rack assembly to cause the receptacle to electricallyengage and disengage with the cable plug.
 17. The electronics rackassembly recited in claim 16, wherein the electronics rack assemblyfurther comprises: a power-up/power-down circuit; an a movement sensorcoupled to the power-up/power-down circuit, wherein the engaging elementforms part of the movement sensor.
 18. The electronics rack assemblyrecited in claim 17, wherein the handle is pivotable between a firstposition and a second position, and wherein the member is to engage themovement sensor in the first position to power-up the at least oneelectronic component, and to disengage the movement sensor in the secondposition to power-down the at least one electronic component.
 19. Theelectronics rack assembly recited in claim 16, wherein the movementsensor comprises a switch.
 20. The electronics rack assembly recited inclaim 16, wherein the member comprises a cam arm and the engagingelement comprises a cam receiver.
 21. The electronics rack assemblyrecited in claim 20, wherein the handle is pivotable between a firstposition and a second position, and wherein the cam arm is to engage thecam receiver in the first position to cause the receptacle to engagewith the cable plug, and to disengage the cam receiver in the secondposition to cause the receptacle to disengage with the cable plug.
 22. Acable management device for use with an electronics rack assembly andwith an electronics tray to be removably mounted in the electronics rackassembly and having at least one electrical receptacle, the cablemanagement device comprising: a clamp comprising a plurality ofopenings, each opening to accommodate a cable plug; and a securingelement to secure the clamp to the electronics rack assembly when theelectrical receptacle of the electronics tray engages with or disengagesfrom a cable plug.
 23. The cable management device recited in claim 22,wherein the plurality of openings are of different physical dimensions.24. The cable management device recited in claim 22, wherein the clampcomprises a pair of mating elements and at least one fastening element.25. The cable management device recited in claim 22, wherein the matingelements comprise retention elements to mate with correspondingretention elements of cable plugs.
 26. An electronics rack assemblycomprising: a pair of opposing sides and a rear side; a cable managementdevice affixed to the rear side and to hold at least one cable plug; andat least one electronics tray comprising: a housing having a base and arear panel; at least one electronic component on the base andelectrically coupled to a receptacle at the rear panel; and mountingelements on the housing to couple to the electronics rack assembly topermit the electronics tray to be inserted substantially within theelectronics rack assembly to couple the receptacle to the cable plug,and to be withdrawn from the electronics rack assembly to uncouple thereceptacle from the cable plug.
 27. The electronics rack assemblyrecited in claim 26, wherein the cable management device is to hold aplurality of cable plugs, and wherein the at least one electronics traycomprises a corresponding plurality of receptacles.
 28. The electronicsrack assembly recited in claim 27, wherein the cable management devicecomprises: a clamp comprising a plurality of openings, each openingbeing dimensioned to accommodate a cable plug; and a securing element tosecure the clamp to the electronics rack assembly.
 29. The electronicsrack assembly recited in claim 28, wherein the cable plugs are ofdifferent physical dimensions.
 30. The electronics rack assembly recitedin claim 28, wherein the clamp comprises a pair of mating elements andat least one fastening element.
 31. The electronics rack assemblyrecited in claim 30, wherein the mating elements comprise retentionelements to mate with corresponding retention elements of cable plugs.32. A cable management device for use with an electronics rack assemblyand with an electronics tray to be removably mounted in the electronicsrack assembly and having at least one electrical connector of a firstgender, the cable management device comprising: a substrate comprising aplurality of traces, the substrate having on a first surface thereof aplurality of cable connectors, each cable connector to accommodate acable plug, the substrate having on a second surface thereof at leastone electrical connector of a second gender that is mateable with the atleast one electrical connector of the first gender, each cable connectorbeing electrically coupled to the at least one electrical connector ofthe second gender through the plurality of traces; and a securingelement to secure the substrate to the electronics rack assembly whenthe at least one electrical connector of the electronics tray engageswith or disengages from the at least one electrical connector of thesubstrate.
 33. The cable management device recited in claim 32, whereinthe plurality of cable connectors are of different physical dimensions.34. The cable management device recited in claim 32, wherein the atleast one electrical connector of the substrate comprises an edgeconnector.
 35. An electronics rack assembly comprising: a pair ofopposing sides and a rear side; a cable management device affixed to therear side and comprising a substrate having a plurality of traces, thesubstrate having on a first surface thereof a plurality of cableconnectors, each cable connector to accommodate a cable plug, thesubstrate having on a second surface thereof at least one electricalconnector of a first gender, each cable connector being electricallycoupled to the at least one electrical connector of the first genderthrough the plurality of traces; and at least one electronics traycomprising: a housing having a base and a rear panel; at least oneelectronic component on the base and electrically coupled to at leastone electrical connector at the rear panel and being of a second genderthat is mateable with the at least one electrical connector of the firstgender; and mounting elements on the housing to couple to theelectronics rack assembly to permit the electronics tray to be insertedsubstantially within the electronics rack assembly to couple the atleast one electrical connector on the rear panel to the at least oneelectrical connector on the substrate, and to be withdrawn from theelectronics rack assembly to uncouple the electrical connectors fromeach other.
 36. The electronics rack assembly recited in claim 35,wherein the cable management device comprises only one electricalconnector of the first gender.
 37. The electronics rack assembly recitedin claim 35, wherein the plurality of cable connectors are of differentphysical dimensions.